Single-phase outer-rotor motor and rotor thereof

ABSTRACT

A single-phase outer-rotor motor includes a stator and a rotor surrounding the stator. The stator includes a stator core and windings wound around the stator core. The stator core includes a yoke and a plurality of teeth. Each of the teeth forms a tooth tip at a distal end thereof. A slot opening is formed between each two adjacent tooth tips. The rotor includes a housing and a permanent magnet affixed to an inside of the housing. The permanent magnet forms a closed ring in a circumferential direction. The permanent magnet forms a plurality of magnetic poles along the circumferential direction. An outer surface of the stator and an inner surface of the permanent magnet define there between a symmetrical uneven gap. A width of the slot opening in the circumferential direction is less than or equal to five times of a minimum width of the gap.

CROSS REFERENCE TO RELATED APPLICATIONS

This non-provisional patent application claims priority under 35 U.S.C.§ 119(a) from Patent Application No. 201510233218.6 filed in ThePeople's Republic of China on May 8, 2015 and Patent Application No.201510627364.7 filed in The People's Republic of China on Sep. 28, 2015.

FIELD OF THE INVENTION

The present invention relates to single-phase motors, and in particularto a single-phase outer-rotor motor.

BACKGROUND OF THE INVENTION

Single-phase motors are commonly used in small power home appliancessuch as, clothes washing machines, dish washers, refrigerators, airconditioners or the like. In terms of the relative positions of thestator and the rotor, the single-phase motors are categorized intoinner-rotor motors and outer-rotor motors. As its name suggests, in asingle-phase outer-rotor motor, the stator is disposed in an interior,the rotor surrounds the stator, and a load can be directly embedded inthe rotor. For the single-phase outer-rotor motor, it has been desiredto reduce the cogging torque of the motor and avoid the dead-pointposition when the rotor stops.

SUMMARY OF THE INVENTION

Thus, there is a desire for an outer-rotor motor and a rotor thereofwhich can effectively avoid the dead-point position of the rotor.

In one aspect, the present invention provides a rotor for a single-phaseouter-rotor motor including a housing and a permanent magnet affixed toan inside of the housing. The permanent magnet is a closed ring in acircumferential direction which includes a plurality of sections alongthe circumferential direction. Each section forms a magnetic pole.Adjacent sections of the permanent magnet have different polarities.Each section of the permanent magnet is an axial symmetrical structure,and a distance between an inner wall surface of each section of thepermanent magnet and a central axis of the rotor progressively variesfrom two circumferential sides toward a center of the inner wallsurface.

Preferably, the distance between the inner wall surface of each sectionof the permanent magnet and the central axis of the rotor progressivelydecreases from the two circumferential sides toward the center of theinner wall surface.

Preferably, the inner surface of each section of the permanent magnet isa flat surface.

Preferably, the inner wall surfaces of the permanent magnet collectivelyform a regular polygon.

In another aspect, the present invention provides a single-phaseouter-rotor motor comprises a stator and a rotor. The stator comprises astator core and windings wound around the stator core. The stator coreincludes a yoke and a plurality of teeth extending outwardly from anouter edge of the yoke, each of the teeth comprising a tooth bodyconnected with the yoke and a tooth tip formed at a distal end of thetooth body. The rotor comprises a housing and at least one permanentmagnet attached to an inside of the housing for forming a plurality ofmagnetic poles. Inner surfaces of the magnetic poles of the rotor andouter surfaces of the tooth tips of the stator define therebetween auneven gap. When the motor is de-energized, the rotor is capable ofbeing positioned at an initial position by a leakage magnetic fieldgenerated by the at least one permanent magnet acting with the toothtips of the stator core.

Preferably, a slot opening is formed between each two adjacent toothtips and a width of the slot opening in a circumferential direction isless than or equal to five times of a minimum gap between the stator andthe rotor.

Preferably, the width of the slot opening in the circumferentialdirection is less than or equal to three times of the minimum gapbetween the stator and the rotor.

Preferably, the tooth tip has a width greater than that of the toothbody. Two circumferential sides of the tooth tip extend beyond the toothbody to respectively form two wing portions. Opposed wing portions ofeach two adjacent tooth tips define one of the slot openings. At leastone of two wing portions adjacent each slot opening is tilted outwardlybefore the windings are wound, and the tilted wing portion deforms tobend inwardly to form the stator core after the windings are wound.

Preferably, the tilted wing portion is formed with a cutting groove and,after the windings are wound, the tilted wing portion deforms to bendinwardly to reduce or eliminate the cutting groove.

In still another aspect, the present invention provides a single-phaseouter-rotor motor, comprising a stator and a rotor surrounding thestator. The stator includes a stator core and windings wound around thestator core. The stator core includes a yoke and a plurality of teethextending integrally and radially outwardly from an outer edge of theyoke. Each of the teeth forms a tooth tip at a distal end thereof. Aslot opening is formed between each two adjacent tooth tips. The rotorincludes a housing and a permanent magnet affixed to an inside of thehousing. The permanent magnet forms a closed ring in a circumferentialdirection. The permanent magnet forms a plurality of magnetic polesalong the circumferential direction. An outer surface of the stator andan inner surface of the permanent magnet define there between asymmetrical uneven gap. A width of the slot opening in thecircumferential direction is less than or equal to five times of aminimum width of the gap.

Preferably, outer wall surfaces of the tooth tips of the stator arelocated on a common cylindrical surface, and inner wall surfaces of thepermanent magnet of the rotor form a regular polygon.

Preferably, the width of the slot opening in the circumferentialdirection is less than or equal to three times of the minimum width ofthe gap.

Preferably, a ratio of a maximum width to the minimum width of the gapis greater than two.

In still another aspect, the present invention provides an electricapparatus comprising a single-phase motor. The motor comprises a statorand a rotor surrounding the stator. The rotor comprises a housing and aring permanent magnet attached to an inside of the housing. The ringpermanent magnet comprises a plurality of sections along acircumferential direction, each section forming a permanent magneticpole, adjacent sections of the permanent magnet having differentpolarities, each section of the permanent magnet having a symmetricalstructure. A distance between an inner surface of each section of thepermanent magnet and a central axis of the rotor progressively increasesfrom a center toward two circumferential sides of the inner surface.

In comparison with the conventional outer-rotor motor, the outer surfaceof the tooth tip of the stator of the motor and the inner surface of themagnetic poles of the rotor define the uneven gap therebetween, whichprevents the rotor from stopping at the dead-point position, thusensuring the successful starting of the rotor when the motor isenergized. In addition, the width of the slot opening in thecircumferential direction is less than or equal to five times of theminimum width of the gap, which can effectively reduce the coggingtorque.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a stator of an outer-rotor motor according to oneembodiment of the present invention.

FIG. 2 is a top view of FIG. 1.

FIG. 3 illustrates a stator core of the stator of FIG. 1.

FIG. 4 is a top view of FIG. 3.

FIG. 5 illustrates the stator core of FIG. 3 prior to the formingthereof.

FIG. 6 is a top view of FIG. 5.

FIG. 7 illustrates a stator core of the stator according to a secondembodiment.

FIG. 8 illustrates the stator core of FIG. 7 prior to the formingthereof.

FIG. 9 illustrates a stator core of the stator according to a thirdembodiment.

FIG. 10 illustrates the stator core of FIG. 9 prior to the formingthereof.

FIG. 11 illustrates a stator core of the stator according to a fourthembodiment.

FIG. 12 illustrates the stator core of FIG. 11 prior to the formingthereof.

FIG. 13 illustrates a stator core of the stator according to a fifthembodiment.

FIG. 14 illustrates the stator core of FIG. 13 prior to the formingthereof.

FIG. 15 illustrates a stator core of the stator according to a sixthembodiment.

FIG. 16 illustrates a stator core of the stator according to a seventhembodiment.

FIG. 17 illustrates a stator core of the stator according to an eighthembodiment.

FIG. 18 illustrates a stator core of the stator according to a ninthembodiment.

FIG. 19 illustrates a rotor of an outer-rotor motor according to oneembodiment of the present invention.

FIG. 20 illustrates a rotor according to a second embodiment.

FIG. 21 illustrates a rotor according to a third embodiment.

FIG. 22 illustrates a rotor according to a fourth embodiment.

FIG. 23 illustrates a rotor according to a fifth embodiment.

FIG. 24 illustrates a motor formed by the stator of FIGS. 1 to 4 and therotor of FIG. 18.

FIG. 25 is an enlarged view of the box X of FIG. 24, with the magneticline removed for clarity.

FIG. 26 illustrates a positional relationship when the motor of FIG. 24is at a dead-point position.

FIG. 27 illustrates a motor formed by the stator of FIGS. 1 to 4 and therotor of FIG. 21.

FIG. 28 illustrates a motor formed by the stator of FIGS. 9 to 10 andthe rotor of FIG. 20.

FIG. 29 illustrates a motor formed by the stator of FIGS. 9 to 10 andthe rotor of FIG. 23.

FIG. 30 illustrates a motor formed by the stator of FIG. 18 and therotor of FIG. 19.

FIG. 31 illustrates a motor formed by the stator of FIG. 17 and therotor of FIG. 18.

FIG. 32 illustrates the motor 1 of the present invention employed in anelectric apparatus.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

To further explain the technical solution and results of the presentinvention, preferred embodiments of the invention will now be describedwith reference to figures of the accompanying drawings.

The single-phase outer-rotor motor includes a stator and a rotorsurrounding the stator. The stator and rotor can have various differentstructures, and different stators and rotors can be combined to resultin motors with different characteristics. FIG. 1 through FIG. 16illustrate multiple embodiments of the stator, FIG. 17 through FIG. 21illustrate multiple embodiments of the rotor, and FIG. 22 through FIG.28 exemplarily illustrate several motors formed by the above stators androtors. It should be understood that the figures are for the purposes ofreference and illustration only. The stator and rotor of the presentinvention are not intended to be limited to the embodiments as shown inthe drawings, and the motors formed by the stators and rotors are alsonot intended to be limited to the embodiments as shown.

FIG. 1 through FIG. 4 illustrate a stator 10 according to a firstembodiment. In this embodiment, the stator 10 includes a stator core 12,an insulating bracket 14 wrapping around the stator core 12, andwindings 16 wound around the insulating bracket 14.

The stator core 12 is made by stacking magnetic-conductive materialssuch as silicon steel sheets. The stator core 12 includes an annularyoke 18, and a plurality of teeth 20 extending integrally and radiallyoutwardly from an outer edge of the yoke 18. The teeth 20 are evenlydisposed along a circumferential direction of the yoke 18. Each tooth 20includes a tooth body 22 connected with the yoke 18 and a tooth tip 24formed at a distal end of the tooth body 22. The tooth body 22 extendsalong a straight line. Preferably, the tooth body 22 extends along aradial direction of the annular yoke 18 A winding slot 26 is formedbetween each two adjacent tooth bodies 22. The winding slot 26 isgenerally sector-shaped, having a width gradually increasing in aradially outward direction from the yoke 18. The tooth tip 24 is overallarc-shaped, which extends generally along a circumferential directionthereof and is generally symmetrical with respect to the tooth body 22.Preferably, each tooth tip 24 is symmetrical with respect to a radius ofthe motor that passes through a center of the tooth body 22 of the tooth20. In the circumferential direction, the tooth tip 24 has a widthgreater than the width of the tooth body 22, and two circumferentialsides of the tooth tip 24 extend beyond the tooth body 22 torespectively form two wing portions 28. In this embodiment, narrow slotopenings 30 are formed between the wing portions 28 of adjacent toothtips 24.

Each tooth tip 24 includes an inner surface 32 facing the tooth body 22,and an outer surface 34 facing the rotor 50. Preferably, the outersurface 34 is an arc surface. The outer surfaces 34 of the tooth tips 24function as an outer surface of the stator 10 and are generally locatedat the same cylindrical surface that is coaxial with the yoke 18 of thestator 10. Cutting grooves 36 are formed in the inner surface 32 of thetooth tip 24. In this embodiment, there are two cutting grooves 36 thatare disposed symmetrically in the two wing portions 28, close to andspaced from the tooth body 22. Each cutting groove 36 extends along aradial direction, i.e. a thickness direction of the tooth tip 24, intothe inner surface 32 of the tooth tip 24. The cutting groove 36 has adepth that is generally a half of the thickness of the tooth tip 24 atthe cutting groove 36, such that the cutting groove 36 does not cause agreat affect to the magnetic path.

The winding 16 is wound around the tooth body 22 and located at an innerside of the tooth tip 24. The winding 16, tooth body 22 and the innersurface 32 of the tooth tip 24 are separated apart by the insulatingbracket 14. The insulating bracket 14 is usually made from a plasticmaterial to avoid short-circuit of the winding 16. As shown in FIG. 5and FIG. 6, prior to winding the windings around the stator core 12, aportion of the tooth tip 24 outside the cutting groove 36 is tiltedoutwardly to enlarge a distance between adjacent tooth tips 24, suchthat the windings 16 can be conveniently wound around the tooth bodies22. After winding is completed, the outer surface 34 of the tooth tip 24is pushed inwardly, making the tooth tip 24 deform to bend toward thetooth body 22, thus forming the arc outer surface 34. During thisprocess, the distance between the tooth tips 24 decreases to narrow theslot opening 30, such that the narrow slot opening 30 is formed, and thecutting groove 36 is narrowed, or even becomes slit-shaped. Preferably,an angle between the portion of the tooth tip 24 outside the cuttinggroove 36 prior to the deformation and the portion after thedeformation, i.e. a deformation angle, is in the range of 15° to 60°.More preferably, the deformation angle of the portion of the tooth tip24 outside the cutting groove 36 is in the range of 20° to 45°.

For stators having the same size, the tooth tip 24 of the stator core 12of the stator 10 is tilted outwardly prior to winding of the windings,which facilitates the winding of the windings. After the winding processis completed, the tooth tip 24 is deformed to bend inwardly. Incomparison with the conventional stator core structure formed bystacking silicon steel sheets that are formed by one-step punching, thetooth tip 24 has a greater width in the circumferential direction, andthe width of the slot opening 30 between the tooth tips 24 issignificantly reduced, preferably, to a half of the width of the slotopening 30 of the conventional stator core structure or even less, whicheffectively reduces the cogging torque. It should be understood that thecutting groove 36 is formed to facilitate the inward bending deformationof the tooth tip 24 and, in some embodiments, the cutting groove 36 canbe omitted if the material of the tooth tip 24 itself has a certaindegree of deformation capability.

FIG. 7 illustrates a stator core 12 of the stator 10 according to asecond embodiment, which is different from the above stator core inthat, each tooth tip 24 of the present embodiment forms the cuttinggroove 36 at only/single one of the wing portions 28. Taking theorientation shown in the figures as an example, each cutting groove 36is formed in the wing portion 28 on the counterclockwise side of thecorresponding tooth body 22. As shown in FIG. 8, prior to the forming ofthe stator core 12, only the wing portion 28 of the tooth tip 24 on thecounterclockwise side of the tooth body 22 is tilted outwardly. Becauseall the wing portions 28 on the same side of the tooth tips 24 aretilted outwardly, each tilted wing portion 28 and the wing portion 28 ofan adjacent tooth tip 24 that is not tilted offset from each other inthe circumferential direction, such that the adjacent wing portions 28can still form a greater distance therebetween for facilitating thewinding. After the winding process is completed, the titled wingportions 28 are bent inwardly which reduces the distance between theadjacent wing portions 28 to form the narrow slot openings 30, thusreducing the cogging torque.

FIG. 9 illustrates a stator core 12 of the stator 10 according to athird embodiment. In comparison with the previous embodiment, the statorcore 12 of the third embodiment is different in that, the cutting groove36 is formed at the connecting area of the wing portion 28 and the toothbody 22, and only one of the two wing portions 28 is tilted outwardlyprior to the winding, as shown in FIG. 10. As such, the cutting groove36 can have a greater depth, the tooth tip 24 can have a greater tiltingangle, and the tooth tips 24 can have a greater distance therebetweenprior to the forming of the stator core, such that the winding can bemore conveniently performed. In addition, it should be understood thatthe connecting areas of both winding portions 28 and the tooth body 22can form the cutting grooves 36, and both wing portions 28 are tiltedoutwardly prior to the winding.

FIG. 11 through FIG. 14 illustrate the stator core 12 of the stator 10according to another two embodiments, which are different in that, sometooth tips 24 form the cutting grooves 36, while some others do not formthe cutting grooves 36. The tooth tips 24 with cutting grooves arealternatively arranged with the tooth tips 24 without the cuttinggrooves. Preferably, the cutting grooves 36 of the tooth tip 24 with thecutting grooves 36 are formed in the two wing portions 28, respectively.Prior to the forming of the stator core, both winging portions 28 aretilted outwardly, which form greater distances with adjacent tooth tipswithout the cutting grooves 36, respectively, to facilitate the winding.The cutting grooves 36 may be respectively formed at the connectingareas of the wing portions 28 and the tooth body 22, as shown in FIG. 11and FIG. 12. Alternatively, the cutting grooves 36 may also be formed atmiddles of the wing portions 28 and spaced from the tooth body 22, asshown in FIG. 13 and FIG. 14.

In the above embodiment, the wing portion 28 of the tooth tip 24 of thestator core 12 is tilted outwardly prior to the winding and deforms tobend inward after the winding. As such, the winding of the windings 16is facilitated, and after the final forming of the stator core, thetooth tip can have a greater width in the circumferential direction toform the smaller slot opening 30, thus reducing the cogging torque. Infact, as long as one of the wing portions 28 at opposite sides of eachslot opening 30 is tilted outwardly, only one or both of the two wingsof each tooth tip 24 of the same stator core 12 can be tilted outwardly,or both of the two wings are not tilted outwardly. The above objectivecan be achieved by combining the wings tilted and the windings nottilted in various suitable patterns not limited to the embodiments asshown in the drawings. In the various embodiments illustrated above, thetooth tips 24 of the stator core 12 are discontinuous along thecircumferential direction, which form therebetween narrow slot openings30. In some other embodiments, the tooth tips 24 may be connected withone another along the circumferential direction, thus minimizing thecogging torque.

FIG. 15 and FIG. 16 illustrate the stator core 12 of the stator 10according to another two embodiments. In these two embodiments, magneticbridges 38 are formed between adjacent tooth tips 24. The magneticbridges 38 integrally connect the tooth tips 24 to collectively form aclosed annular edge. Preferably, the closed annular edge has a minimumradial thickness at a position of the magnetic bridge 38. Morepreferably, one or more axially extending grooves 40 are formed in aninner surface of the magnetic bridge 38. As shown, each magnetic bridge38 forms a plurality of the grooves 40 evenly arranged along thecircumferential direction. In order for the winding to be performed, thetooth tip may be separated apart from the tooth body 22 at a connectionarea therebetween (as shown in FIG. 15). As such, after the windingprocess is completed, the annular edge collectively formed by the toothtips 24 is again connected around the tooth bodies 22 along an axialdirection to form the stator core 12. In the embodiment illustrated inFIG. 16, the tooth bodies 22 are separated apart from the yoke 18 atconnection areas therebetween and, after the winding is processed, theyoke 18 is assembled within the tooth bodies 22 to form the stator core12.

FIG. 17 and FIG. 18 illustrate the stator core 12 according to anothertwo embodiments. The constructions of the stator core 12 of these twoembodiments are generally the same as the embodiments of FIG. 15 andFIG. 16, respectively, except that, an outer circumferential surface 34of the tooth tip 24 is provided with a positioning groove 42 which isdisposed in the wing portion 28 and deviates from a center of the toothtip 24, such that the tooth tip 24 is asymmetrical with respect to aradius of the motor that passes through a center of the tooth body 22 ofthe tooth 20.

FIG. 19 through FIG. 23 illustrate the rotor 50 according to variousembodiments of the present invention. The rotor 50 is an outer rotor,including a housing 52 and one or multiple permanent magnets 54 affixedto an inside of the housing 52. An outer circumferential surface of thepermanent magnet 54 is affixed to the housing 52, which may bepositioned with adhesive or integrally connected by insert molding. Aninner surface 56 of the permanent magnet 54 defines a space for mountingthe stator 10 therein. The space is slightly greater than the stator 10in size, such that the stator 10 and the rotor 50 define a gaptherebetween.

FIG. 19 illustrates the rotor 50 according to a first embodiment. Inthis embodiment, the permanent magnet 54 includes multiple split magnetsarranged evenly along the circumferential direction of the housing 52,and a gap is formed between each two adjacent permanent magnets 54. Eachpermanent magnet 54 functions as one permanent magnetic pole of therotor 50, and adjacent permanent magnets 54 have opposite polarities. Inthis embodiment, each permanent magnet 54 is a part of a circular ring,and the inner face 56 of the permanent magnet 54 facing the stator 10 isan arc surface. The inner surfaces 56 of all the permanent magnets 54form the inner surface of the rotor 50, which are located on the samecylindrical surface coaxial with the rotor 50. If any one of the statorsdescribed above is mounted in the rotor 50, a radial distance betweenthe outer surface of the tooth tip 24 of the stator 10 and the innersurface 56 of the permanent magnet 54 of the rotor 50 is constant alongthe circumferential direction and, therefore, the stator and rotor 10,50 define a substantially even gap therebetween.

Preferably, a pole-arc coefficient of each permanent magnet 54, i.e. aratio of the spanning angle α of the permanent magnetic pole 54 to aquotient of 360 degrees by the rotor pole number N, i.e. α:360/N, isgreater than 0.7, which can improve the torque characteristics of themotor and enhance the motor efficiency. In various embodiments of thestator 10 and rotor 50 of the motor, the number of the permanent magnets54 is the same as the number of the teeth 20, i.e. the magnetic poles ofthe stator 10 and the rotor 50 are the same. As shown, there are eightpermanent magnets 54 and eight teeth 20, the eight magnets 54 form eightmagnetic poles of the rotor 50, and the eight teeth 20 definetherebetween eight winding slots 26, thereby cooperatively forming an8-pole 8-slot motor. In other embodiments, the number of the teeth 20 ofthe stator 10 may have a multiple relation with the number of thepermanent magnets 54 of the rotor 50. For example, the number of theteeth 20 is two or three times of the number of the permanent magneticpoles 54. Preferably, the windings 16 of the stator 10 are electricallyconnected and supplied with a single-phase direct current electricity bya single-phase brushless direct current motor driver, thus forming asingle-phase direct current brushless motor. In another embodiment, thedesign of the present invention may be equally applicable as asingle-phase permanent magnet synchronous motor.

FIG. 20 through FIG. 23 illustrate the rotor 50 according to severalother embodiments. In these embodiments, the inner circumferentialsurface 56 of the magnet 54 is not a cylindrical arc surface and, afterthe stator 10 is mounted, the stator 10 and rotor 50 define therebetweenan uneven gap. These embodiments are described in detail below.

FIG. 20 illustrates the rotor 50 according to a second embodiment. Inthe second embodiment, the permanent magnet 54 is symmetrical about itsmiddle line which extends along the thickness direction of the magnet54. The permanent magnet 54 has a thickness progressively decreasingfrom a circumferential center to two circumferential sides of thepermanent magnet 54. The inner surface 56 of each permanent magnet 54facing the stator 10 is a flat surface extending parallel to atangential direction of a radial outer surface of the stator. Eachpermanent magnet 54 forms a permanent magnetic pole. In a radialcross-section as shown in FIG. 20, the inner surfaces of the permanentmagnets 54 are located on sides of a regular polygon, respectively. Assuch, the gap formed between the permanent magnetic poles 54 and thestator 10 is a symmetrical uneven gap. The size of the gap has a minimumvalue at a position corresponding to the circumferential center of thepermanent magnet 54, and progressively increases from position of theminimum value toward two circumferential sides of the permanent magnet54. The provision of the symmetrical uneven gap facilitates positioningthe rotor 50 at a position deviating from a dead-point position when themotor is powered off, such that the rotor 50 can be successfully startedwhen the motor is energized.

FIG. 21 illustrates the rotor 50 according to a third embodiment, whichis different from the embodiment of FIG. 20 mainly in that the permanentmagnet 54 is an integral structure in the shape of a closed ring in thecircumferential direction. The ring-shaped permanent magnet 54 includesa plurality of sections in the circumferential direction. Each sectionfunctions as one magnetic pole of the rotor 50, and adjacent sectionshave different polarities. Similar to each permanent magnet 54 of therotor 50 of FIG. 20, each section of the permanent magnet 54 has athickness progressively decreasing from a circumferential center to twocircumferential sides. The inner surface 56 of each section facing thestator 10 is a flat surface. In a radial cross-section as shown in FIG.21, all sections of the permanent magnet 54 cooperatively form a regularpolygonal inner surface of the rotor 50. Similar to the embodiment ofFIG. 20, the gap formed between each magnetic pole of the permanentmagnet 54 and the outer surface of the stator 10 is a symmetrical unevengap.

FIG. 22 illustrates the rotor 50 according to a fourth embodiment, whichis similar to the embodiment of FIG. 20, the rotor 50 includes aplurality of permanent magnets 54 spacingly arranged in thecircumferential direction, and each permanent magnet 54 has a flat innercircumferential surface 56. Differently, in this embodiment, thepermanent magnet 54 is an asymmetrical structure having a thicknessprogressively increasing from one circumferential side toward the othercircumferential side, and progressively decreasing from a positionadjacent the other circumferential side. The permanent magnet 54 has amaximum thickness at a position deviating from a circumferential centerof the permanent magnet 54, and the two circumferential sides of thepermanent magnet 54 have different thickness. Connecting lines betweentwo end sides of the inner surface 56 of the permanent magnet 54 and acenter of the rotor 50 form a un-isosceles triangle. As such, afterassembled with the stator 10, the stator 10 and rotor 50 define anuneven asymmetrical gap there 1 between. The provision of theasymmetrical uneven gap facilitates positioning the rotor 50 at aposition deviating from a dead-point position when the motor is poweredoff, such that the rotor 50 can be successfully started when the motoris energized.

FIG. 23 illustrates the rotor 50 according to a fifth embodiment. Inthis embodiment, the rotor 50 includes a housing 52, and a plurality ofpermanent magnets 54 and magnetic members 58 affixed to an inner side ofthe housing 52. The magnetic members 58 may be made from a hard magneticmaterial such as ferromagnet or rare earth magnets, or a soft magneticmaterial such as iron. The permanent magnets 54 and the magnetic members58 are spacingly alternatively arranged in the circumferentialdirection, with one magnetic member 58 inserted between each twoadjacent permanent magnets 54. In this embodiment, the permanent magnet54 is column-shaped having a generally square cross-section. Each twoadjacent permanent magnets 54 define therebetween a large space whichhas a circumferential width far greater than that of the permanentmagnet 54. As such, the magnetic member 58 has a larger circumferentialwidth than the permanent magnet 54, which width may be several times ofthe width of the permanent magnet 54.

The magnetic member 58 is symmetrical about a radius of the rotor whichpass through a middle of the magnetic member 58. The magnetic member 58has a thickness progressively decreasing from a circumferentialmiddle/center to two circumferential sides thereof. A minimum thicknessof the magnetic member 58, i.e. the thickness at its circumferentialsides, is substantially the same as that of the permanent magnet 54. Theinner circumferential surface 60 of the magnet member 58 facing thestator 10 is a flat surface extending parallel to a tangential directionof an outer surface of the stator 10. As such, the inner circumferentialsurfaces 56 of the permanent magnets 54 and the inner circumferentialsurfaces 60 of the magnetic members 58 collectively form the innersurface of the rotor 50 which is a symmetrical polygon in a radialcross-section of the rotor 50. After the rotor 50 is assembled with thestator 10, the gap formed between the stator 10 and the rotor 50 is asymmetrical uneven gap. Preferably, the permanent magnet 54 ismagnetized along the circumferential direction, i.e. circumferentialside surfaces of the permanent magnet 54 are polarized to havecorresponding polarities. Two adjacent permanent magnets 54 haveopposite polarization direction. That is, two adjacent surfaces of thetwo adjacent permanent magnets 54 that are opposed to each other havethe same polarity. As such, the magnetic member 58 between the twoadjacent permanent magnets 54 are polarized to the correspondingmagnetic poles, and two adjacent magnetic members 58 have differentpolarities.

Motors with different characteristics can be obtained from differentcombinations of the above stators 10 and rotors 50, some of which areexemplified below.

FIG. 24 illustrates a motor formed by the stator 10 of the firstembodiment illustrated in FIG. 1 through FIG. 4 and the rotor 50illustrated in FIG. 20. The tooth tips 24 of the stator 10 are spacedapart in the circumferential direction to form the slot openings 30, andthe outer surfaces 34 of the tooth tips 24 are located on the samecylindrical surface, such that the whole outer surface of the stator 10is circular in shape. The permanent magnetic poles 54 of the rotor 50are spaced apart in the circumferential direction, and the inner surface56 of the permanent magnetic pole 54 facing the stator 10 is a flatsurface, such that the whole inner surface of the rotor 50 is a regularpolygon in shape. The outer surface 34 of the stator 10 and the innersurface 56 of the rotor 50 are radially spaced apart to form a gap 62.The gap 62 has a radial width varying along the circumferentialdirection of the permanent magnetic pole 54, which is a symmetricaluneven gap 62 which is symmetrical about the middle line of thepermanent magnetic pole 54. The radial width of the gap 62 progressivelyincreases from the circumferential center toward the two circumferentialsides of the inner surface 56 of the permanent magnet 54.

Referring also to FIG. 25, the radial distance between thecircumferential center of the inner surface 56 of the permanent magnet54 and the outer surface 34 of the tooth tip 24 is the minimum widthGmin of the gap 62, and the radial distance between the circumferentialsides of the inner surface 56 of the permanent magnet 54 and the outersurface 34 of the tooth tip 24 is the maximum width Gmax of the gap 62.Preferably, a ratio of the maximum width Gmax to the minimum width Gminof the gap is greater than 1.5, i.e. Gmax:Gmin>1.5. More preferably,Gmax:Gmin>2. Preferably, the width D of the slot opening 30 is notgreater than five times of the minimum width Gmin of the gap 62, i.e.D≤5 Gmin. Preferably, the width D of the slot opening 30 is equal to orgreater than the minimum width Gmin of the gap 62, but less than orequal to three times of the minimum width Gmin of the gap 62, i.e.Gmin≤D≤3 Gmin.

Referring to FIG. 24 and FIG. 26, when the motor is not energized, thepermanent magnets 54 of the rotor 50 produce an attractive force whichattracts the teeth 20 of the stator 10. FIG. 24 and FIG. 26 show therotor 50 at different positions. Specifically, FIG. 26 shows the rotor50 in a dead-point position (i.e. a center of the magnetic pole of therotor 50 is aligned with a center of the tooth tip 24 of the stator 10).FIG. 24 shows the rotor 50 in an initial position (i.e. the stopposition of the rotor 50 when the motor is not energized or poweredoff). As shown in FIG. 24 and FIG. 26, the magnetic flux of the magneticfield produced by the magnetic pole of the rotor 50 that passes throughthe stator 10 is Φ1 when the rotor 50 is at the dead-point position, themagnetic flux of the magnetic field produced by the magnetic pole of therotor 50 that passes through the stator 10 is Φ2 when the rotor 50 is atthe initial position. Because Φ2>Φ1 and the path of Φ2 is shorter thanthat of Φ1 and the magnetic resistance of Φ2 is less than that of Φ1,the rotor 50 can be positioned at the initial position when the motor isnot energized, thus avoiding stopping at the dead-point position shownin FIG. 24 and hence avoiding the failure of starting the rotor 50 whenthe motor is energized.

Referring to FIG. 24, at this initial position, the middle line of thetooth tip of the stator is closer to the middle line of the neutral areabetween two adjacent magnetic poles 54 than middle lines of the twoadjacent magnetic poles 54. Preferably, a middle line of the tooth tip24 of the tooth 20 of the stator 10 is aligned with the middle line ofthe neutral area between two adjacent permanent magnetic poles 54. Thisposition deviates the furthest from the dead-point position, which caneffectively avoid the failure of starting the rotor when the motor isenergized. Due to other factors such as friction in practice, at theinitial position the middle line of the tooth tip 24 may deviate fromthe middle line of the neutral area between two adjacent permanentmagnet poles 54 by an angle such as an angle of 0 to 30 degrees, but theinitial position is still far away from the dead-point position. In theabove embodiments of the present invention, the rotor 50 can bepositioned at the initial position deviating from the dead-pointposition by the leakage magnetic field produced by the permanent magnets54 of the rotor 50 acting with the tooth tips 24 of the stator. Theleakage magnetic flux produced by the permanent magnets 54 does not passthrough the tooth bodies 22 and the windings 16. The cogging torque ofthe single-phase permanent magnet brushless motor configured as such canbe effectively suppressed, such that the motor has enhanced efficiencyand performance. Experiments show that a peak of the cogging torque of asingle-phase outer-rotor brushless direct current motor configured asabove (the rated torque is 1 Nm, the rated rotation speed is 1000 rpm,and the stack height of the stator core is 30 mm) is less than 80 mNm.

FIG. 27 illustrates a motor formed by the stator 10 of the firstembodiment illustrated in FIG. 1 through FIG. 4 and the rotor 50 of thethird embodiment illustrated in FIG. 21. The tooth tips 24 of the stator10 are spaced apart in the circumferential direction to form the slotopenings 30, and the outer surfaces 34 of the tooth tips 24 are locatedon the same cylindrical surface. The permanent magnet 54 of the rotor 50includes multiple sections connected to each other in thecircumferential direction, each section functions as one magnetic poleof the rotor 50, and the inner circumferential surface 56 of themagnetic pole is a flat surface, such that the inner surface of thewhole rotor 50 is a regular polygon in shape. The stator 10 and therotor 50 form therebetween the symmetrical uneven gap 62, the width ofthe gap 62 progressively increases from two circumferential sides towardthe circumferential center of each magnetic pole, with the maximum widthGmax at the circumferential center of the magnetic pole and the minimumwidth Gmin at the circumferential sides. When the rotor 50 is still, thecenter of each tooth tip 24 is aligned with a junction of twocorresponding sections of the permanent magnet 54, which avoids thedead-point position to facilitate restarting of the rotor 50.

FIG. 28 illustrates a motor formed by the stator 10 of the thirdembodiment illustrated in FIG. 9 and FIG. 10 and the rotor 50 of thefourth embodiment illustrated in FIG. 22. The tooth tips 24 of thestator 10 are spaced apart in the circumferential direction to form theslot openings 30, and the outer circumferential surfaces 34 of the toothtips 24 are located on the same cylindrical surface. The permanentmagnet of the rotor 50 is an asymmetrical structure having annon-uniform thickness along the circumferential direction. The innercircumferential surface 56 of the permanent magnet 54 of the rotor 50 isinclined an angle relative to a tangential direction of the outercircumferential surface 34 of the tooth tip 24, and the innercircumferential surface 56 of the permanent magnet 54 and the outercircumferential surface 34 of the tooth tip 24 define therebetween anuneven asymmetrical gap 62. The width of the gap 62 firstlyprogressively decreases from one circumferential side toward the othercircumferential side of the permanent magnet 54, and then progressivelyincreases. Taking the orientation illustrated in the drawings as anexample, the gap 62 has the maximum width Gmax at a clockwise side ofthe permanent magnet 54, and the minimum width Gmin of the gap 62 is ata position adjacent but deviating from a counterclockwise side of thepermanent magnet 54.

FIG. 29 illustrates a motor formed by the stator 10 of the thirdembodiment illustrated in FIG. 9 and FIG. 10 and the rotor 50 of thefifth embodiment illustrated in FIG. 23. The tooth tips 24 of the stator10 are spaced apart in the circumferential direction to form the slotopenings 30, and the outer surfaces 34 of the tooth tips 24 are locatedon the same cylindrical surface. The rotor 50 includes the permanentmagnets 54 and the magnetic members 58 that are spacingly alternativelyarranged in the circumferential direction. The inner surfaces 56 of thepermanent magnets 54 and the inner surfaces 60 of the magnetic members58 collectively form the polygonal inner surface of the rotor 50. Thestator 10 and the rotor 50 form therebetween a symmetrical uneven gap62, which has a size progressively decreasing from a circumferentialcenter to two circumferential sides of the magnetic member 58, andreaches the maximum width Gmax at the position corresponding to thepermanent magnet 54. The rotor 50 is capable of being positioned at theinitial position by leakage magnetic flux circuits each of which passesthrough a permanent magnetic pole 54, two adjacent magnetic members 58and a corresponding tooth tip 24. At the initial position, a center ofthe permanent magnet 54 is radially aligned with a center of the toothtip 24, such that the permanent magnet 54 applies a circumferentialforce on the stator 10 to facilitate the start of the rotor 50.

FIG. 30 illustrates a motor formed by the stator 10 illustrated in FIG.17 and the rotor 50 illustrated in FIG. 19. The tooth tips 24 of thestator 10 are connected to each other in the circumferential direction,and the whole outer surface of the stator 10, i.e. the outer surface 34of the tooth tip 24 is a cylindrical surface. The inner surface of therotor 50, i.e. the inner circumferential surfaces 56 of the permanentmagnets 54, are located on a cylindrical surface coaxial with the outercircumferential surface 34 of the stator 10. The outer circumferentialsurface 34 of the stator 10 and the inner circumferential surface 56 ofthe rotor 50 define an even gap 62. The outer circumferential surface 34of the tooth tip 24 is provided with positioning grooves 42, which makesthe tooth tip 24 have an asymmetrical structure, thereby ensuring that,when the rotor 50 is still, a center line of the area between twoadjacent permanent magnets 54 deflects an angle relative a center lineof the tooth tip 24 of the tooth 20 of the stator 10. Preferably, whenthe rotor is still, the positioning slot 42 of the stator 10 is alignedwith the center line of the two adjacent permanent magnets 54 of therotor 50, which enables the rotor 50 to successfully start each time themotor is energized. Understandably, in this embodiment, the tooth tips24 of the stator 10 may be separated from each other via a narrow slotopening in the circumferential direction.

FIG. 31 illustrates a motor formed by the stator 10 of the sixthembodiment illustrated in FIG. 15 and the rotor 50 of the secondembodiment illustrated in FIG. 20. The tooth tips 24 of the stator 10are connected to each other in the circumferential direction, and thewhole outer surface of the stator 10 is a cylindrical surface. The innercircumferential surface 56 of the permanent magnet 54 of the rotor 50 isa flat surface extending parallel to a tangential direction of an outersurface of the stator 10. The inner circumferential surface 56 of thepermanent magnet 54 and the outer circumferential surface 34 of toothtip 24 form therebetween an symmetrical uneven gap 62. The width of thegap 62 progressively decreases from a circumferential center to twocircumferential sides of the permanent magnet 54, with a minimum widthGmin at the circumferential center of the permanent magnet 54 and amaximum width Gmax at the two circumferential sides.

FIG. 32 illustrates the motor 1 of the present invention employed in anelectric apparatus 4 according to another embodiment. The electricapparatus 4 may be a range hood, a ventilation fan, or an airconditioner which comprises an impeller 3 driven by the rotor shaft 21of the motor. The electric apparatus 4 may also be a washing machine ora dry machine which comprises a speed reducing device 3 driven by therotor 50 of the motor.

It should be understood that the stators 10 of FIG. 1 through FIG. 11are substantially the same in construction and characteristics, whichform narrow slot openings or even have no slot openings, and which canbe interchanged to realize the same function when combined with therotor 50. In addition, depending on the different gaps formed betweenthe stator and rotor and depending on the symmetry and asymmetry of thestator and rotor structures, suitable circuits can be designed to enablethe rotor 50 to successfully start when the motor is energized. Itshould be understood that combinations of the stator 10 and the rotor 50is not limited to the embodiments exemplified above. Variousmodifications without departing from the spirit of the present inventionfall within the scope of the present invention. Therefore, the scope ofthe invention is to be determined by reference to the claims thatfollow.

The invention claimed is:
 1. A single-phase outer-rotor motor,comprising: a stator comprising a stator core and windings wound aroundthe stator core, the stator core includes a yoke and a plurality ofteeth extending outwardly from an outer edge of the yoke, each of theteeth comprising a tooth body connected with the yoke and a tooth tipformed at a distal end of the tooth body, the windings are wound aroundthe tooth bodies; and a rotor surrounding the stator, wherein the rotorcomprises: a housing; and at least one permanent magnet attached to aninside of the housing, the at least one permanent magnet being a closedring in a circumferential direction which includes a plurality ofsections along the circumferential direction, each section forming amagnetic pole, a distance between an inner surface of each section ofthe permanent magnet and a central axis of the rotor progressivelydecreasing from two circumferential sides toward a center of the innersurface, wherein inner surfaces of the magnetic poles of the rotor andouter surfaces of the tooth tips of the stator define therebetween anuneven gap, the number of the magnetic poles of the rotor is equal tothe number of the teeth of the stator, a slot opening is formed betweeneach two adjacent tooth tips, and a width of the slot opening in acircumferential direction is equal to or greater than a minimum gapbetween the stator and the rotor, but less than or equal to five timesthe minimum gap between the stator and the rotor.
 2. The single-phaseouter-rotor motor of claim 1, wherein the width of the slot opening inthe circumferential direction is less than or equal to three times ofthe minimum gap between the stator and the rotor.
 3. The single-phaseouter-rotor motor of claim 1, wherein the tooth tip has a width greaterthan that of the tooth body, two circumferential sides of the tooth tipextend beyond the tooth body to respectively form two wing portions,adjacent wing portions of each two adjacent tooth tips define one of theslot openings, at least one of two wing portions adjacent each slotopening is tilted outwardly before the windings are wound, and thetilted wing portion deforms to bend inwardly after the windings arewound.
 4. The single-phase outer-rotor motor of claim 3, wherein thetilted wing portion is formed with a cutting groove and, after thewindings are wound, the tilted wing portion is deformed to bend inwardlyto reduce or eliminate the cutting groove.
 5. The single-phaseouter-rotor motor of claim 1, wherein the at least one permanent magnetis an integral permanent magnet.
 6. The single-phase outer-rotor motorof claim 1, wherein when the motor is de-energized, the rotor is capableof being positioned at an initial position by a leakage magnetic fieldgenerated by the at least one permanent magnet acting with the toothtips of the stator core.
 7. The single-phase outer-rotor motor of claim6, wherein outer surfaces of the tooth tips of the stator are located ona common cylindrical surface, and inner surfaces of the permanent magnetof the rotor form a regular polygon.
 8. The single-phase outer-rotormotor of claim 1, wherein adjacent sections of the permanent magnet hasdifferent polarities, each section of the permanent magnet having asymmetrical structure.
 9. The single-phase outer-rotor motor of claim 1,wherein a ratio of a maximum width to the minimum width of the gap isgreater than two.
 10. An electric apparatus, comprising a single-phasemotor of claim
 1. 11. The electric apparatus of claim 10, wherein awinding slot is formed between each two adjacent tooth tips, and thewindings are wound around the tooth bodies.
 12. The electric apparatusof claim 10 is a range hood, an air conditioner, or a ventilation fanwhich further comprises an impeller driven by the motor.
 13. Theelectric apparatus of claim 10 is a washing machine or dry machine whichfurther comprises a speed reducing device driven by the motor.
 14. Theelectric apparatus of claim 10, wherein a ratio of a maximum width tothe minimum width of the gap is greater than two.
 15. The electricapparatus of claim 10, wherein outer surfaces of the tooth tips of thestator are located on a common cylindrical surface, and inner surfacesof the permanent magnet of the rotor form a regular polygon.